nickel compounds of the formula (R1 COO) (R2 COO) Ni, where R1 is hydrocarbyl of at least 5 carbon atoms and R2 is haloalkyl of 1-3 carbon atoms, are manufactured from the corresponding acids R1 COOH and R2 COOH or salts thereof. The resultant nickel compounds are soluble in hydrocarbons and can be used in admixture with organoaluminum compounds as constituents of catalytic compositions; olefins can be oligomerized, for example, dimerized and trimerized, therewith.
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1. A new nickel compound of the general formula (R1 COO) (R2 COO)Ni, where R1 is a hydroxy substituted or unsubstituted hydrocarbyl radical containing 5-20 carbon atoms and R2 is a haloalkyl group comprising 1 to 3 carbon atoms.
2. A new nickel compound according to
3. A nickel compound according to
4. A compound according to
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The present invention relates to new bivalent nickel compounds, their manufacture and use as components of catalytic compositions for oligomerizing olefins.
Bivalent nickel inorganic salts are well-known. They are usually soluble in an aqueous medium and have little solubility, if any, in a hydrocarbon medium. Conversely, bivalent nickel salts of carboxylic acids of the formula (RCOO)2 Ni, where R is a substituted or unsubstituted hydrocarbyl radical, are usually soluble, sometimes in large amounts, in hydrocarbon media, provided the radical R has a sufficient number of carbon atoms. This property is often desired when the nickel salts must be used as homogeneous catalysts, either alone or associated with Lewis acids, such as alkylaluminum compounds. It is true that the use of insoluble nickel salts as catalysts has several known disadvantages, particularly a weaker activity as compared with soluble salts and difficulties of use, particularly in continuous industrial operations where precise and particularly low proportions of catalyst must be used. This explains why it has already been proposed to prepare soluble oligomerization catalysts, such as catalysts for dimerizing or co-dimerizing mono-olefins, by reacting nickel carboxylates with hydrocarbyl aluminum halides.
The use of these catalysts has, however, the disadvantage that the activity observed in continuous operations is often lower than in batch operations, and even tends to decrease in the course of time. No satisfactory explanation of this phenomenon has yet been found.
The object of the present invention is precisely to provide new mixed nickel compounds, soluble in hydrocarbon media, which, when used with hydrocarbyl aluminum halides in oligomerization operations, have increased catalytic activity and stability, particularly as concerns continuous operations. This activity is even higher than that obtained by joint use of a nickel carboxylate, a halogenoacetic acid and a hydrocarbyl aluminum halide, as disclosed in U.S. application Ser. No. 102,488. These new compounds are also useful, when associated with alkyl aluminum compounds, as catalysts for diolefin polymerization.
These new mixed nickel compounds are of the general formula (R1 COO) (R2 COO)Ni, where R1 is a hydrocarbyl radical, for example an alkyl, cycloalkyl, alkenyl, aryl, aralkyl or alkaryl radical, containing at least 5 carbon atoms, preferably a hydrocarbyl radical of 5-20 carbon atoms, which radical may be substituted with, for example, hydroxy groups, and R2 is a halogenoalkyl radical containing from 1 to 3 carbon atoms, of the formula Cm Hp Xq, where m is 1, 2 or 3, p is zero or an integer and q is an integer, provided that p+q=2m+1. R2 is preferably a halogenomethyl radical CXn H3-n where X is fluorine, chlorine, bromine or iodine and n is an integer from 1 to 3.
The high activity of the catalytic compositions obtained from the above nickel compounds and hydrocarbyl aluminum halides is the more unexpected as the catalytic compositions obtained from nickel bis (halogenoacetates) and hydrocarbyl aluminum halides have themselves a relatively poor activity, probably due to the insolubility of these nickel compounds in hydrocarbon media. The new nickel compounds according to the invention have conversely a substantial solubility in hydrocarbon media, i.e. a solubility of at least 0.1 g per liter under the conditions of use.
The mixed compounds (R1 COO) (R2 COO)Ni may be manufactured by reacting the mixture of the two acids R1 COOH and R2 COOH in substantially equimolecular quantities with nickel metal or a nickel oxide, hydroxide or carbonate. They can also be prepared in aqueous medium by contacting water-soluble alkali metal salts (including ammonium salts) of the two acids R1 COOH and R2 COOH in proportions which are preferably substantially equimolecular, with a bivalent nickel salt soluble in water. Examples of useful salts are nickel chloride, nickel bromide, nickel iodide, nickel sulfate and nickel nitrate and their hydrates. The alkali metal salts may be formed in situ by using organic acids and operating in the presence of a base providing the alkali metal.
The reaction is preferably effected in a liquid two phase medium comprising an aqueous phase and a substantially immiscible organic phase, consisting of aliphatic, cycloaliphatic or aromatic hydrocarbons or mixtures thereof, or of halogenated hydrocarbons, for example, chlorinated, fluorinated or brominated hydrocarbons. Use may be made of, for example, pentane, heptane, petroleum ether, naphtha, cyclohexane, toluene, xylenes, ethylbenzene, methylene chloride or chloroform. The aqueous phase and the alkali metal salt formed by double decomposition are separated thereafter.
According to another operating procedure, the mixture of the alkali metal salts of the two acids R1 COOH and R2 COOH may be prepared in a lower alcohol having, for example, 1 to 4 carbon atoms, for example, methanol or ethanol, and the nickel salt is added thereafter. After reaction, the alcohol is removed at least in a major part, by distillation and is replaced with a hydrocarbon or a halogenated hydrocarbon as above described. The inorganic salts can then be eliminated by filtration.
According to a modified embodiment, the mixture of the alkali metal salts of the two acids R1 COOH and R2 COOH may be prepared in a mixed medium comprising an alcohol, for example methanol or ethanol, and a hydrocarbon or a halogenated hydrocarbon as above described. The composition of the alcohol-hydrocarbon mixture may be selected at will; for example, the mixture may have the same composition as the azeotrope, if any, formed by the two solvents. The alcohol or solvent mixture can be removed thereafter.
Another operating procedure, which also leads to the mixed compounds (R1 COO) (R2 COO)Ni, consists of separately preparing, according to known methods, the two compounds (R1 COO)2 Ni and (R2 COO)2 Ni and then reacting these two compounds in substantially equimolecular proportions in a liquid medium comprising a polar solvent, for example, water or an alcohol, and a non-polaar solvent, for example a hydrocarbon or a halogenated hydrocarbon, and subsequently eliminating the polar solvent by distillation.
When using free acids as starting compounds, the base providing the alkali metal is preferably used in substantially stoichiometric amount with respect to the two acids in the form of, for example, sodium or potassium hydroxide, or the corresponding carbonates or hydrogenocarbonates, or ammonia.
It may however be advantageous, in order to facilitate the isolation of the nickel salt, to operate with a slight insufficiency, for example of 5-30%, with respect to the stoichiometry, of one of the reactants, for example an insufficient amount of the base.
The acids or their salts may be used in stoichiometric proportions with respect to the nickel salt, but different proportions can also be used. Thus an excess of nickel salt, for example a molar excess of 5 to 20%, is favorable to the recovery of a pure product.
The order of supply of the reactants is not critical. However it is preferred to admit first the two acids R1 COOH and R2 COOH with the base in a polar medium, so as to obtain the salts, and then introduce the nickel salt and the hydrocarbon phase.
The proportion of water or alcohol to be used is not critical; however, according to the invention, the best results are obtained with the minimum amount necessary to dissolve the reactants at the reaction temperature. The amount of hydrocarbon phase must be sufficient to dissolve the mixed salt. It then depends on the nature of the reactants; a preferred amount is selected between 2 and 100 times the amount of water or alcohol.
The reaction temperature depends on the reaction facilities; it is however preferred to heat the reaction mixture at reflux under atmospheric pressure, or at a higher or lower pressure, up to stable coloration of the organic phase. This operation may take from 5 minutes to 5 hours, depending on the reflux temperature.
The polar phase, containing the inorganic salts, may be withdrawn by decantation and discharged; it has, however, been observed, and this is another particular feature of the invention, that particularly high reaction velocities and yields, as concerns the mixed nickel compounds, are obtained by heteroazeotropic distillation of the polar solvent. This distillation is preferably continued up to complete removal of the polar phase. In that case, the resultant inorganic salts are separated by decantation or filtration. The hydrocarbon or halogenated hydrocarbon solvent may be evaporated or distilled and the nickel compound may be isolated as a generally amorphous green solid; for specific uses, however, it can be used as a solution.
Another object of the present invention is to use these mixed bivalent nickel salts as components of a new catalyst composition useful for oligomerizing, and particularly dimerizing and trimerizing mono-olefins. This new composition concerns more precisely the combinations obtained by contacting, in any order, at least one mixed nickel salt with at least one hydrocarbyl aluminum halide.
The following compounds may be used, alone or as mixtures, the list being however not limitative; nickel 2-ethylbutyrate trifluoroacetate, nickel 2-ethylbutyrate trichloroacetate, nickel 3,3-dimethylbutyrate trifluoroacetate, nickel 3,3-dimethylbutyrate trichloroacetate, nickel 4-methylvalerate trifluoroacetate, nickel hexanoate trichloroacetate, nickel heptanoate trifluoroacetate, nickel heptanoate trichloroacetate, nickel heptanoate tribromoacetate, nickel heptanoate triiodoacetate, nickel 2-ethylhexanoate trifluoroacetate, nickel 2-ethylhexanoate monofluoroacetate, nickel 2-ethylhexanoate trichloroacetate, nickel 2-ethylhexanoate dichloroacetate, nickel 2-ethylhexanoate monochloroacetate, nickel 2-ethylhexanoate tribromoacetate, nickel 2-ethylhexanoate triiodoacetate, nickel octoate trifluoroacetate, nickel octoate trichloroacetate, nickel decanoate trifluoroacetate, nickel decanoate trichloroacetate, nickel myristate trifluoroacetate, nickel palmitate trifluoroacetate, nickel dodecylbenzoate trifluoroacetate, nickel diisopropylsalicylate trichloroacetate, nickel myristate pentafluoropropionate and nickel 2-ethylhexanoate heptafluorobutyrate.
Preferred hydrocarbylaluminum halides conform to with the general formula Al2 Rx Yy where R is a hydrocarbon group containing up to 12 carbon atoms, or more, such as alkyl, aryl, aralkyl, alkaryl, cycloalkyl; Y represents halogen: fluorine, chlorine, bromine or iodine; x and y have each a value of 2,3 or 4 with x+y=6. Examples of such compounds are ethyl aluminum sesquichloride, dichloroethylaluminum, dichloroisobutylaluminum, chlorodiethylaluminum or their mixtures. Examples of catalyst compositions consist of any one of the mixed nickel compounds of the above list and any one of the aluminum compounds mentioned above.
The invention has also for an object, a process for oligomerizing mono-olefins in the presence of the above catalytic compositions at a temperature of -20°C to +80°C at pressure conditions such that the reactants are maintained, at least in a major part, in the liquid or condensed phase.
Mono-olefins which can be dimerized or oligomerized are, for example, ethylene, propylene, n-butenes, n-pentenes, either pure or as mixtures such as recovered from synthesis processes, for example, catalytic cracking or steam-cracking. They can be co-oligomerized either together or with isobutene, for example, ethylene with propylene and n-butenes, propylene with n-butenes or n-butenes with iso-butene.
The concentration, expressed as nickel, of the catalytic composition in the liquid phase of the oligomerization reaction, is normally comprised between 5 and 500 parts per million by weight. The molar ratio of the hydrocarbyl aluminum halide to the nickel compound is normally comprised between 1:1 and 50:1, more advantageously between 2:1 and 20:1.
The process may be operated with separate charges but offers a maximum of advantages when operated continuously. In that case, a reactor with one or more serially arranged reaction stages may be used, the olefinic charge and/or the catalyst constituents being continuously introduced either into the first stage or in the first and any other stage. The second and nth stage may also be fed only with additional amounts of one constituent of the catalytic mixture.
At the outlet of the reactor, the catalyst may be deactivated in a known manner, for example, with ammonia and/or an aqueous sodium hydroxide solution and/or an aqueous sulfuric acid solution. The unconverted olefins and the alkanes, if any, are separated thereafter from the oligomers by distillation.
The following examples illustrate the invention but constitute no limitation thereof. The characteristic portion of the infra-red absorption spectrum of the compounds obtained in examples 1 to 5 is shown in FIGS. 1 to 5 (Nujol, KBr). A is the wave length in microns and B the wave number in cm-1.
14.4 g of 2-ethyl hexanoic acid (0.1 mole), 200 cm3 of heptane, 11.4 g of trifluoroacetic acid (0.1 mole), 10.6 g of sodium carbonate, 23.7 g of nickel chloride hexahydrate (0.1 mole) and 25 cm3 of water are successively introduced into a 500 cm3 glass reaction vessel provided with a magnetic stirring rod and a device for heteroazeotropic distillation. The contents are heated to reflux and water is eliminated by azeotropic distillation. An insoluble precipitate containing NaCl is filtered and washed with heptane; the organic phase is evaporated under vacuum. There remains a solid of intense green color, which is identified by elemental analysis and infra-red spectrometry as nickel 2-ethyl hexanoate trifluoroacetate. Elemental analysis: calculated for C10 H15 O4 F3 Ni: C=38.1; H=4.8; Ni=18.7; found (%): C=38.7; H=5.6; Ni=16.9. Infra-red spectrum: characteristic bands at 1670 cm-1 (CF3 COO), 1575 and 1410 cm-1 (C7 H15 COO), 1205 and 1150 cm-1 (CF3). 29.5 g of the mixed salt have been obtained, corresponding to a yield of 93.1%.
It has been proved that the above salt is a mixed compound and not a mixture of nickel trifluoroacetate with nickel 2-ethyl hexanoate: nickel trifluoroacetate is insoluble in hydrocarbons; if formed, it would have been eliminated in the solid state and the yield of hydrocarbon-soluble compound would have been far lower.
The operation is conducted as in example 1, while successively introducing: 80 cm3 of heptane, 5 cm3 or water, 0.91 g of trifluoroacetic acid (8×10-3 mole), 1.04 g of heptanoic acid (8×10-3 mole), 0.64 g of sodium hydroxide (1.6×10-2 mole) and finally 2.81 g of nickel sulfate heptahydrate (10-2 mole). A green solid is obtained (weight: 2.23 g; yield: 88.8%) identified as being nickel heptanoate trifluoroacetate. Elemental analysis: calculated for C9 H13 O4 F3 Ni: C=35.9; H=4.3; F=18.9; Ni=19.6; found (%) C=35.6; H=4.5; F=18.7; Ni=19.1. Infra-red spectrum: characteristic bands at 1675 cm-1 (CF3 COO), 1570 cm-1 (C6 H13 COO), 1205 and 1150 cm-1 (CF3).
The operation is conducted as in example 1, while reacting: 80 cm3 of heptane, 5 cm3 of water, 0.91 g of trifluoroacetic acid (8×10-3 mole), 1.71 g of myristic acid (8×10-3 mole), 0.64 g of sodium hydroxide (1.6×10-2 mole) and 2.81 g of nickel sulfate heptahydrate (10-2 mole). A green solid (2.80 g) is obtained and identified as being nickel myristate trifluoroacetate (yield: 90.9%). Elemental analysis: calculated for C15 H25 O4 F3 Ni: C=46.8; H=6.5; F=14.8; Ni=15.3; found (%) C=47.7; H=7.1; F=14.4; Ni=14.8. Infra-red spectrum: characteristic bands at 1675 cm-1 (CF3 COO), 1580 and 1410 cm-1 (C12 H25 COO), 1205 and 1150 cm-1 CF3).
The operation is conducted as in example 1, while reacting: 100 cm3 of heptane, 25 cm3 of water, 5.75 g of 2-ethyl hexanoic acid (4×10-2 mole), 6.55 g of trichloroacetic acid (4×10-2 mole), 3.20 g of sodium hydroxide (8×10-2 mole) and 14.05 g of nickel sulfate heptahydrate (5×10-2 mole). A green solid is obtained (10.8 g), which is identified as being nickel 2-ethyl hexanote trichloroacetate (yield: 74.2%). Elemental analysis: calculated for C10 H15 O4 Cl3 Ni: C=32.9; H=4.1; Ni=16.2; found (%) C=37.5; H=5.7; Ni=15.2. Infra-red spectrum: characteristic bands at 1655 cm-1 (CCl3 COO), 1570 and 1410 cm-1 (C7 H15 COO), 845 and 835 cm-1 (CCl3).
The process is conducted as in example 1, while reacting: 80 cm3 of heptane, 5 cm3 of water, 0.91 g of tricluoroacetic acid (8×10-1 mole), 0.93 g of 4-methyl valeric acid (8×10-3 mole), 0.64 g of sodium hydroxide (1.6×10-2 mole) and then 2.81 g of nickel sulfate heptahydrate (10-2 mole). A green solid is obtained (0.6 g) and identified as being nickel 4-methyl valerate trifluoroacetate (yield: 26%). Elemental analysis: calculated for C8 H11 O4 F3 Ni: C=33.4; H=3.8; Ni=20.5; found (%) C=33.3; H=3.9; Ni=20.1. Infrared spectrum: characteristic bands at 1675 cm-1 (CF3 COO), 1570 and 1410 cm-1 (C5 H11 COO), 1200 and 1145 cm-1 (CF3).
An oligomerization reactor consists of two serially arranged reaction stages, each consisting of a double-jacket cylindrical steel reactor of a useful volume of 0.25 liter, whose temperature is controlled by circulating water.
The first stage reactor is continuously fed with 98 g/h of a C4 cut whose composition is as follows:
propane: 1.1% b.w.
isobutane: 6.7
n-butane: 23.0
1-butene: 5.2
trans 2-butene: 46.4
cis 2-butene: 17.6
The reactor is also fed with 0.031 g/h of nickel 2-ethyl hexanoate trifluoroacetate prepared as in example 1, as a solution in heptane, and 0.194 g/h of dichloroethylaluminum as a solution in heptane. A pressure of 5 bars is maintained in the reactors by continuously discharging the reaction product, and the temperature is maintained at 42°C by means of circulating water.
After 4 hours of run, a steady state run is obtained, corresponding to a 66% conversion of the butenes to oligomers in the first stage and 75% at the outlet of the second stage. The oligomers comprise 85% dimers (n-octenes, methylheptenes and dimethylhexenes), 12% trimers and 3% tetramers.
The activity of the catalyst system, expressed as the velocity constant k (mol-1.l.h-1) defined by the relation V=kC2, where V is the reaction velocity (mol.l-1.h-1) and C the butenes stationary concentration (mol.l-1) in the stages, is:
k (first stage): 0.423 mol-1.l.h-1
k (second stage): 0.106 mol-1.l.h-1
The apparatus is the same as in example 6 and it is continuously fed with 83 g/h of the same C4 cut, 0.036 g/h of nickel 2-ethyl hexanoate trichloroacetate prepared as in example 4 in the form of a solution in heptane, and 0.194 g/h of dichloroethylaluminum as a solution in heptane.
After 4 hours of run, a steady state operating rate is attained, corresponding to a butenes conversion of 64% in the first stage and 77% at the outlet of the second stage.
The activity of the catalyst system, expressed as in example 6, is:
k (first stage): 0.307 mol-1.l.h-1
k (second stage): 0.152 mol-1.l.h-1
This example is given by way of comparison for showing the advantages of the invention.
The apparatus is the same as in example 6. It is continuously fed with 82 g/h of the same C4 cut, 0.052 g/h of a nickel carboxylate having a 11% b.w. nickel content, admixed with 0.011 g/h of trifluoroacetic acid in heptane, and 0.194 g/h of dichloroethylaluminum as a solution in heptane.
The amount of nickel, expressed in g/h of Ni metal, is thus identical to that used in example 6, which permits a direct comparison of the results by means of the constant k.
The steady state operating rate attained after 4 hours of run corresponds to a 57% conversion in the first stage and 68% at the outlet of the second stage. The activity of the catalyst system is thus substantially lower than in example 6:
k (first stage): 0.193 mol-1.l.h-1
k (second stage): 0.067 mol-1.l.h-1
14.4 g of 2-ethyl hexanoic acid (0.1 mole), 100 cm3 of methanol, 11.4 g of trifluoroacetic acid (0.1 mole) and 8.0 g of sodium hydroxide (0.2 mole) are successively fed into a 500 cm3 glass reaction vessel provided with a magnetic stirring rod and a reflux device. The mixture is heated to reflux and 35.1 g (0.125 mole) of nickel sulfate heptahydrate is added. The mixture is heated again at reflux. Methanol is evaporated by means of a rotary evaporator and the residue is taken up in toluene. After filtration of the insoluble inorganic salts, toluene is distilled off and nickel 2-ethyl hexanoate trifluoroacetate is obtained. Its analysis corresponds to the formula C10 H15 O4 F3 Ni and it has the same characteristic bands as the product of example 1.
An oligomerization reactor of 35 liter useful volume is continuously fed with 5 kg/h of a C3 cut having the following composition:
propane: 20% b.w.
propylene: 80% b.w.
0.273 g/h of nickel 2-ethyl hexanoate trifluoroacetate as a solution in isooctane and 1.65 g/h dichloroethylaluminum as a solution in isooctane are added. A pressure of 15 bars is maintained by withdrawal of reaction product and a temperature of 42°C by water circulation. The conversion of propylene to oligomers under steady state conditions amounts to 90% and the resultant oligomers comprise 85% of dimers (n-hexenes, methylpentenes and dimethylbutenes), 12% of trimers and 3% of tetramers.
25 g of NiO, 46 cm3 of trifluoroacetic acid and 90 cm3 of distilled water are introduced into a 1-liter glass reaction flask provided with a magnetic stirring rod and a distillation device. The mixture is heated at reflux for 2 hours; then the excess of NiO is filtered. An aqueous solution of nickel trifluoroacetate Ni(CF3 COO)2 is thus obtained in quantitative yield. 135 g of nickel 2-ethyl hexanoate (13% b.w. nickel content) of technical grade, containing 10% of free 2-ethyl hexanoic acid, dissolved in 500 cm3 heptane, are added. After heating at reflux, water is removed by azeotropic distillation. After complete water removal, heptane is separated by evaporation under vacuum. Nickel 2-ethyl hexanoate trifluoroacetate is thus obtained with a yield of 98%. Elemental analysis: calculated for C10 H15 O4 F3 Ni: C=38.1; H=4.8; Ni=18.7; found: C=38.4; H=5.4; Ni=17.8. The infra-red spectrum shows the expected characteristic bands identical to those of example 1.
The above nickel compound has been used to prepare an oligomerization catalyst and to oligomerize a C4 cut under the same conditions as in example 6.
The conversion was 66% in the first stage and 75% at the outlet of the second stage and the oligomers analyzed substantially as in example 6.
To summarize, the mixed salts of the invention may be prepared by reacting a source of R1 COO--ion in solution with a source of R2 COO--ion in solution and a source of nickel ion (which may be common with the two above sources) in solution. The solvent used for the dissolution may be common to all the sources or distinct solvents may be used. A polar solvent, preferably water and/or an alcohol, is commonly used. Simultaneously, or subsequently, a hydrocarbon solvent or a halogenated hydrocarbon solvent is added and the polar solvent is removed, preferably by distillation. The mixed salt is obtained as a solution in the hydrocarbon or the halogenated hydrocarbon.
Commereuc, Dominique, Chauvin, Yves, Le Pennec, Dominique
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| Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
| Aug 04 1980 | LE PENNEC, DOMINIQUE | INSTITUT FRANCAIS DU PETROLE, RUEIL-MALMAISON, FRANCE | ASSIGNMENT OF ASSIGNORS INTEREST | 003909 | /0272 | |
| Aug 04 1980 | COMMEREUC, DOMINIQUE | INSTITUT FRANCAIS DU PETROLE, RUEIL-MALMAISON, FRANCE | ASSIGNMENT OF ASSIGNORS INTEREST | 003909 | /0272 | |
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